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High performance electrically conductive epoxy/reduced graphene oxide


adhesives for electronics packaging applications

Article  in  Journal of Materials Science Materials in Electronics · January 2019


DOI: 10.1007/s10854-019-00722-5

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Journal of Materials Science: Materials in Electronics
https://doi.org/10.1007/s10854-019-00722-5

High performance electrically conductive epoxy/reduced graphene


oxide adhesives for electronics packaging applications
Ruchi Aradhana1 · Smita Mohanty1,2 · Sanjay Kumar Nayak1,2

Received: 22 July 2018 / Accepted: 9 January 2019


© Springer Science+Business Media, LLC, part of Springer Nature 2019

Abstract
In the present study, an attempt has been done to prepare an electrically conductive epoxy adhesive filled with the high
content of reduced graphene oxide (rGO) (i.e. 10–50 wt%). The lap shear test was performed to study the adhesive strength
of epoxy-based adhesive systems. The test results revealed that adhesive with 40 wt% rGO possessed highest shear strength
which is 72.8% higher over unmodified epoxy. While the tensile test results showed a decrement of 33% in tensile strength
even with the introduction of 10 wt% rGO. The unnotched and notched impact strength of epoxy resin found to be increas-
ing up to 51% and 100% respectively, when 30 wt% rGO was incorporated within the matrix. The fractography analysis of
notched impact samples was examined by scanning electron microscopy and unveils that crack pinning is the toughening
mechanism for E–rGO adhesive systems. The dispersion assessment of rGO within the epoxy matrix was visualized by
transmission electron microscopy technique, revealing the effective distribution of rGO in epoxy matrix. The volume and
surface conductivity was increased up to 3.44 × 10−08 S/m and 8.54 × 10−06 S with 50 wt% rGO addition, which are five and
five-fold higher in comparison to the epoxy resin. At 35 °C, the thermal conductivity was enhanced by ~ 408% as compared
to pristine epoxy, when 50 wt% rGO was included. Fourier transform infra‑red spectroscopy spectra was used to study the
nature of interaction between rGO and epoxy matrix. The adhesive systems showed higher thermo-stability with the intro-
duction of rGO as detected by thermo-gravimetric analysis technique.

1 Introduction properties of polymers [5]. Among the preparation methods


of graphene (i.e. thermal or chemical reduction), chemical
Graphene, a monolayer of two-dimensional sheet consists reduction process through graphene oxide (GO) layers has
of ­sp2-bonded carbon atoms arranged in an atomically thick been most frequently researched route owing to their cost-
honeycomb structure, has seized the attention of research- effectiveness [6], scalability and production in bulk quanti-
ers in both scientific community and industries [1, 2]. As a ties [1]. Typically, the graphene derivative produced by the
thinnest [2] and strongest [1] material, it possesses many above-mentioned process termed as reduced graphene oxide
outstanding properties such as excellent strength (130 GPa), (rGO). rGO, a derivative of graphene with some structural
high modulus (1000 GPa) [2], large surface area (2600 m2/g), defects, considered as promising functional nanofiller for
high thermal conductivity (4.84 × 103–5.30 × 103 W/mK) electrically conductive adhesives (ECAs) due to their high
[3] and electrical conductivity (around 6000 S/m) [4], etc. inherent electrical conductivity [7], excellent mechanical,
Even a low volume fraction of graphene is sufficient to thermal, optical properties [8] and their ability for large-
effectively improve the mechanical, electrical and thermal scale production [9].
With the increasing demand for higher input/output
counts and miniaturization, various novel electronics pack-
* Ruchi Aradhana aging materials are continuously being developed [10].
aradhanaruchi@yahoo.com
Although the development has been considerably advanced
1
Central Institute of Plastics Engineering & Technology over the past few decades, the vital requirements for the die
(CIPET), TVK Industrial Estate, Guindy, Chennai, attach and interconnects among all the electronic compo-
Tamil Nadu 600032, India nents remain unchanged [11]. The components should be
2
Laboratory for Advanced Research in Polymeric Materials electrically connected to power, have high purity, fast curing
(LARPM), Central Institute of Plastics Engineering & time, lower stress, high package crack resistance, etc [11,
Technology (CIPET), Bhubaneswar, Odisha, India

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Vol.:(0123456789)
Journal of Materials Science: Materials in Electronics

12]. Therefore, polymer based ECAs are effectively replac- 10 to 50, and labelled as ­R10, ­R20, ­R30, ­R40, and ­R50. The
ing the tin–lead solders owing to their advantages such as lap shear test of adhesive formulations was performed using
environmental friendliness, lower processing temperature, aluminium substrates for studying the adhesive strength.
fewer processing steps, fine pitch capability, long service life The tensile strength and izod impact strengths (for notched
and lower cost, etc [11]. At the same time, more and more and unnotched specimens) were calculated for a detailed
functional materials at their nanoscale are being utilized in examination of the mechanical properties of adhesive for-
electronic packaging applications for improving the adhe- mulations. The fractographic study of notched impact sam-
sion and electrical conductivity, such as i.e. carbon nano- ples was investigated using scanning electron microscopy
tubes (CNT) [13, 14], vapor grown carbon nanofiber and (SEM) technique. The dispersion of rGO fillers within the
graphene [15, 16], etc. epoxy adhesive was visualized using transmission electron
Conventionally, ECAs were fabricated by distributing microscopy (TEM). The directional electrical conductivity
effective electrically conductive fillers throughout the insu- (i.e. volume and surface conductivity) of adhesive samples
lating thermosetting resins. Epoxy resins are a class of versa- were inspected using super megaohmmeter and the thermal
tile thermoset polymers widely used as conductive adhesives conductivity ­(Tc) of conductive adhesives was studied by uti-
in diverse fields such as electronic packaging. This includes lizing the guarded hot plate method. The chemical structure
solder-less interconnections, display interconnections, com- of rGO, nature of interaction between rGO and epoxy was
ponent renovation, die fittings [17]; and aerospace [18], etc. studied by Fourier transform infra‑red spectroscopy (FTIR).
Epoxy resin generally used as matrix material for adhesive The thermo-stability and thermal degradation temperature
systems due to their high mechanical properties, outstanding of adhesive systems was examined by Thermo-gravimetric
adhesion behaviour, excellent thermal and chemical resist- analysis (TGA).
ance [19], lower shrinkage [18] and acceptability of wide-
ranging additives and substrates [19], etc. There are a few lit-
eratures concerning epoxy/rGO conductive nanocomposites/ 2 Materials and methods
adhesives and their various applications [1, 5, 20]. Bindu
et al. [1] developed microwave exfoliated reduced graphene 2.1 Materials
oxide (MERGO) filled epoxy nanocomposites and witnessed
excellent AC conductivity (i.e. ­10−5 S/m) with the addition Epoxy resin diglycidyl ether of bisphenol A (DGEBA),
of 5 wt% MERGO. Pokharel et al. [5] investigated the elec- Araldite GY250, Epoxy equivalent: 170–190 g/kg) and ali-
trical percolation threshold of epoxy composites incorpo- phatic amine curing agent (triethylenetetramine (TETA),
rated with rGO. The rGO was synthesized by multi-step Aradur HY951, specific gravity: 0.98 g/cm3) were procured
microwave reduction of graphite oxide and the researchers from Huntsman Int Pvt. Ltd, Mumbai, India. The rGO with
observed ­106.2 Ω/sq surface resistivity with 0.3 wt% RGO avg. 4–8 no of layers, specific surface area: 180 m2/g and
filling. Yosefi et al. [20] prepared rGO/waterborne epoxy 99% purity was purchased from Platonic Nanotech Pvt. Ltd.,
(EP) composite through in situ polymerization and studied India. Common chemical such as acetone was acquired from
electrical conductivity across in-plane and through-thick- Merck specialists Pvt. Ltd. India. The aluminium substrates
ness directions. The percolation threshold was found to be used for lap shear testing was purchased from Krishna
0.12 vol%, while the conductivity was increased eightfold Homesmith Pvt. Ltd., India and cut in the dimension of
when 0.5 wt% rGO was added. Sharmila et al. [21] examined 101.6 × 25.4 × 1.62 mm using CNC milling machine. All the
AC electrical conductivity of hybrid composites of epoxy chemicals and materials were used as received for the fabri-
and reduced graphene oxide/iron oxide (RGO–Fe2O3), and cation of adhesive formulations. The chemical structures of
found maximum of ­10−4 S/m with 5 phr RGO–Fe2O3 loading DGEBA, TETA and rGO are shown in Fig. 1.
at 30 MHz frequency. Li et al. [15] studied the volume resis-
tivity of epoxy composite comprising of copper nanowires 2.2 Fabrication of E–rGO conductive adhesives
(CuNWs) and rGO hybrid filler. They found that CuNWs/
NH2–rGO/epoxy exhibited lowest volume resitivity with a To study the influence of rGO with high concentration in
value of 2.69 × 1011 Ω cm as compared to CuNWs/epoxy the epoxy matrix, pristine epoxy adhesive (E), rGO filled
and ­NH2–rGO/epoxy polymer composite. To the best of our epoxy conductive adhesives with different wt% such as 10,
knowledge, no literature has been reported concerning rGO/ 20, 30, 40 and 50 wt% (labelled as R­ 10, ­R20, ­R30, ­R40, ­R50)
epoxy conductive adhesives with high volume fraction rGO were prepared. The composition of all epoxy-based adhe-
loading and their mechanical, electrical and thermal proper- sive formulations are entered in Table 1 and the fabrication
ties so far. method is illustrated in Fig. 2.
In the present work, epoxy conductive adhesives were To secure proper dispersion, rGOs were initially dis-
developed with the inclusion of rGO by varying wt% from persed in 30–40 mL of acetone using ultrasonication (6.5 L

13
Journal of Materials Science: Materials in Electronics

at room temperature for 7 days and further post-cured at


100 °C for 1 h and another 1 h at 130 °C. Che et al. [23] fab-
ricated graphene oxide sheets–zirconia spheres ­(ZrO2–rGO)
nanohybrids as a reinforcement for epoxy composites. They
have prepared the Z ­ rO2–rGO/epoxy composites by following
procedure: first the epoxy monomer was heated at 60 °C in
a drying oven. The Z ­ rO2–rGO was first dispersed in acetone
with the integrated high-shear mixing and followed by ultra-
sonication. Then mixed with the epoxy oligomer at 80 °C
with vigorous stirring for 30 min. For removal of bubbles,
the above mixture then intensely stirred for 2 h at 60 °C
Fig. 1  Chemical structure of DGEBA epoxy resin, TETA, and rGO
under ultrasonic surroundings. Afterwards, a stoichiometric
amount of DDM (curing agent) was mixed thoroughly by
stirring for 1 h at 60 °C. Then the mixture was degassed in
capacity, M/s Deluxe Trading Co., India) for 30 min and con- a vacuum oven for 30 min at 60 °C. Finally, the mixture was
currently, DGEBA resin was kept in a vacuum oven at 35 °C poured into a preheated mould and cured at 100 °C for 2 h,
for around 30 min for avoiding trapped airs. The rGO and followed by further heating at 150 °C for 2 h. As the afore-
acetone mixture was then mixed with the pristine DGEBA mentioned researchers used composite or nanohybrid fillers
resin utilizing an overhead stirrer (M/s Remi Electrotechnik as the reinforcement for epoxy composites, it is essential to
Ltd., Vasai) at 1000–1500 rpm for 60 min to ensure effective follow additional processes for effective dispersion of fill-
mixing. Further, the mixture was subjected to ultrasonication ers and complete curing of the composites. However, in this
for 30 min to achieve thorough dispersion of rGO within the work, single filler i.e. rGO was used as a reinforcement to
base resin. The reaction mixture was then degassed in a vac- enhance the performance of epoxy adhesives.
uum oven for 30 min at 50 °C to conduct two activities such
as withdrawing air bubbles and evaporating the remaining
acetone. Lastly, the curing agent was mixed with the result-
ing mixture for 5–11 min by retaining 100:13 w/w epoxy 3 Characterizations
resin: curing agent ratio. The mixture was applied to alumin-
ium substrates and poured into a metallic mould, then cured 3.1 Lap shear test
with the following curing procedure such as first at ambient
temperature for 1 day and s, for post-curing at 80 °C for 4 h The adhesive strength for unmodified epoxy and epoxy con-
[19]. Various researcher groups have been utilized different ductive adhesives was determined by performing lap shear
types of method of preparation for epoxy/rGO composites. test of two aluminium substrates (101.6 × 25.4 × 1.62 mm
For instance, Lin et al. [22] reported regarding the prepara- dimension) bonded together with 12.7 mm overlapped area
tion of epoxy coatings by incorporating a composite filler as per ASTM D-1002. The tests were performed by utilizing
[poly(styrenesulfonate)–polyaniline/reduced graphene oxide the Universal testing machine (UTM, 3382 Instron Instru-
(PSS–PANI/rGO)] and rGO. The authors first blended the ments Ltd, UK) with a crosshead speed of 1.27 mm/min for
bisphenol-A type epoxy resin with various amounts of rGO around five samples and mean result was recorded.
or PSS–PANI/rGO by utilizing a tri-roller mill. Then, the
curing agent was added into the above mixture by mechani-
cal agitation while maintaining the weight ratio of 11:20
(for curing agent: epoxy). Subsequently, they were cured

Table 1  Various epoxy-based Coding Sample Quantity (g) Acetone (mL)


adhesives composition
Epoxy resin Curing agent rGO

E Epoxy 130 13 – –
R10 Epoxy–10 wt% rGO 119 13 11.90 30
R20 Epoxy–20 wt% rGO 108 13 21.60 30
R30 Epoxy–30 wt% rGO 100 13 30 30
R40 Epoxy–40 wt% rGO 93 13 37.2 35
R50 Epoxy–50 wt% rGO 87 13 43.50 40

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Journal of Materials Science: Materials in Electronics

Fig. 2  Schematic diagram for the fabrication of E–rGO conductive adhesive systems

3.2 Tensile test utilizing an Impact tester, (IT 504 Plastic Impact, M/s
Tinius Olsen, USA).
The tensile strength, elongation at break and modulus for
E and ­R10–R50 adhesive systems were studied at 1 mm/ 3.4 Scanning electron microscopy (SEM)
min crosshead speed using the Universal testing machine
(UTM, LR-100NK, 3382 Instron Instruments Ltd, UK) in The fractography evaluation of E, R­ 10, ­R30 and R
­ 50 adhesive
accord with ASTM D-638 standard. The specimens with formulations later izod impact testing for notched specimens
the length of 33  mm, grip area of 18.7  mm and thick- was analyzed with 5 keV accelerating voltage and 50 µm
ness of 3 mm were cut by CNC cutter and mean value scale bar by employing SEM (EVO MA15, M/s Carl Zeiss
was reported after testing at least five samples of each SMT, Germany). The notched impact samples were sputter
adhesive. coated by Au/Pd mixture (to avoid electric discharge) before
the analysis.

3.3 Impact test 3.5 Transmission electron microscopy (TEM)

Impact strength (for both notched and unnotched speci- TEM (JEM-1400, JEOL, Japan) for E–rGO conductive adhe-
mens possess 64.5 × 12.7 × 3.2 mm dimension) for unmod- sive formulation was used to study the extent of dispersion
ified epoxy and E–rGO adhesive formulations were cal- of rGO layers in the epoxy matrix with 80–100 KeV accel-
culated according to the standard of ASTM D-256 by erating voltage. The samples were prepared as an ultra-thin

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Journal of Materials Science: Materials in Electronics

section using Leica microtome and placed on a copper grid The shear strength of epoxy resin unveils noticeable incre-
prior to TEM imaging. ment when rGO layers are inserted within the unmodified
epoxy resin. This increasing trend endures up to a pleatue
3.6 Electrical conductivity (i.e. 40 wt% rGO), afterward decreases with higher rGO con-
tent. The E exhibited 5.43 MPa shear strength and adhesive
The electrical conductivity [volume (σv) and surface (σs)] failure mode which usually causes by the adherent-adhesive
for epoxy based conductive adhesive systems compared with interface fracture (shown in Fig. 3b). When rGO incorpo-
unmodified epoxy was determined in accord with ASTM rated with varying wt% i.e. 10, 20, 30 and 40 wt%, the shear
D-257 standard (employing 100 mm diameter and 3 mm strength substantially increased by about 18%, 22.3%, 45%
thick round disk) by utilizing Super megaohmmeter (SM- and 72.8% in comparison to the base epoxy. In comparison
8220, M/s TOA Electronics Ltd, Japan). to the ­R40 adhesive formulation, the ­R50 adhesive possessed
shear strength of 6.08 MPa which is 35% lower. In addi-
tion, the failure mode of all conductive adhesives is modified
3.7 Thermal conductivity
from adhesive to partially cohesive or fully cohesive failure
as indicated by Fig. 3c–g. This modification of failure modes
The thermal conductivity of E and ­R10–R50 adhesive formu-
signifies better bonding efficiency of conductive adhesives
lations was measured by following guarded hot plate method
after rGO inclusion. Similar trends have been detected in our
according to ASTM E-1530 standard and using Thermal
previous paper [19] and by Singh et al. [24, 25] with rein-
conductivity tester (Unitherm 2022, M/s Anter Corpo,
forcement of different nanomaterials. The improvement of
USA). A circular disk with a diameter of 50 mm and thick-
shear strength can be imputed to the good interfacial interac-
ness of 3 mm for each adhesive formulation was evaluated
tion between the rGO and the epoxy resin owing to (i) the
over four varying temperatures of 35, 55, 75 and 95 °C.
covalent bonding of oxygen functional groups of rGO with
epoxide group of DGEBA resin and (ii) large surface area
3.8 FTIR spectroscopy of rGO layers. This leads to effective load transfer between
matrix and filler resulting in higher cohesion strength of
FTIR spectra were examined to study the functional groups the adhesive formulations with Al substrates. Similar type
of rGO along with to explore the nature of interaction results have been noticed by Kumar et al. [26] and Norhakim
between the rGO filler and the epoxy matrix. The samples et al. [27]. The diminution of shear strength at higher rGO
were scanned over 4000 to 400 cm−1 wavelength by using content can be credited to the incompatible dispersion. As
Continuum Nicolet 6700, M/s Thermo Electron Corpora- the filler content increases, the resin viscosity also increases
tion, USA. simultaneously decreasing the flow rate of epoxy resin. This
decreased flow rate develops the micro-voids which sub-
3.9 Thermo‑gravimetric analysis (TGA) sequently deteriorates the shear strength of the adhesive.
Similar findings have been witnessed by Adak et al. [28]
The thermo-stability and thermal degradation temperature in the case of thermally reduced graphene oxide reinforced
for cured E and ­R30 adhesive systems were analysed by woven carbon fiber/epoxy composite.
using TGA (Q-50, M/s TA Instruments, USA). The 6–10 mg
weight samples were heated over 30–800 °C temperature 4.2 Tensile test
range at a 10 °C/min heating rate as per ASTM E-1868
standard. The mechanical performance examined through tensile tests
including tensile strength, tensile modulus, and elongation at
break are summarized in Table 3 and respective stress versus
4 Results and discussion strain graphs are presented in Fig. 4.
From Table 3, it is clearly witnessed that the rGO inclu-
4.1 Lap shear test sion into the epoxy resin resulted in lower tensile strength
than that of the base resin. The tensile strength of pristine
The shear stress versus shear strain curves of the epoxy and epoxy was found to be 47.45 MPa. When rGO particles
its conductive adhesives with varying wt% of rGO are rep- are incorporated, the tensile strength decreased by around
resented in Fig. 3a. The shear strength and different failure 33%, 26.4%, 11%, 35% and 36.4% for R ­ 10, ­R20, ­R30, ­R40
modes of E and R ­ 10–R50 adhesive formulations are listed in and ­R50 adhesive formulations as compared to unmodi-
Table 2. Figure 3b–g depicts the failure mode of all adhesive fied epoxy. The diminution can be imputed to the altera-
formulations which reveal transition from adhesive failure tion of the stoichiometric ratio between epoxide groups
to partially or fully cohesive failure. of DGEBA resin and amine groups of TETA by the rGO

13
Journal of Materials Science: Materials in Electronics

Fig. 3  a Shear stress versus


strain graphs of E and ­R10–R50
adhesive formulations; Different
failure modes of b E, c ­R10, d
­R20, e ­R30, f ­R40, g ­R50

Table 2  Adhesive strength (lap shear strength) and different failure Table 3  Tensile properties of E and ­R10–R50 conductive adhesive for-
modes of epoxy adhesive with various wt% of rGO mulations
Sample Shear strength (MPa) Failure mode Sample Tensile strength Tensile modulus Elongation
(MPa) (MPa) at break (%)
E 5.43 ± 0.86 Adhesive
R10 6.41 ± 0.74 Partially cohesive E 47.45 ± 7.2 2624.62 ± 79 1.57 ± 0.92
R20 6.64 ± 0.91 Partially cohesive R10 31.74 ± 8.1 3148.26 ± 86 1.32 ± 0.72
R30 7.88 ± 0.63 Partially cohesive R20 34.91 ± 6.5 3565.74 ± 63 1.43 ± 0.81
R40 9.38 ± 0.82 Fully cohesive R30 42.13 ± 7.9 2851.48 ± 74 2.39 ± 0.67
R50 6.08 ± 0.97 Partially cohesive R40 31.05 ± 5.4 3577.30 ± 92 1.26 ± 0.78
R50 30.17 ± 6.2 3751.95 ± 66 1.13 ± 0.70

content which eventually participates in crosslinking


reaction and disturbs the curing process of epoxy resin about 10% and 33%, respectively. However, the strength of
[29].The ­R 10 adhesive formulation exhibit 31.74  MPa adhesives comprising 40 and 50 wt% rGO were diminished
tensile strength. The tensile strength of adhesive sys- by 2.21% and ~ 5% as compared to ­R10 adhesive formula-
tems increased gradually up to 30 wt% rGO inclusion and tion. The higher tensile strength of R
­ 20–R30 adhesive sys-
afterwards decreased with higher rGO loading (i.e. 40 tems can be clarified by studying the possible interactions
and 50 wt%). In comparison to the R ­ 10 system, the ten- between DGEBA resin, rGO and TETA as illustrated in
sile strength of ­R20 and ­R30 adhesives were improved by Scheme 1. The oxygen functional groups present on the

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Journal of Materials Science: Materials in Electronics

4.3 Impact test

To study the reinforcing effect of rGO with varying content


(i.e. high wt%) on epoxy adhesives, izod impact strength (for
unnotched and notched samples) were calculated and listed
in Table 4. The variation of impact strength for adhesive
systems versus rGO concentration is plotted in Fig. 5.
The unnotched and notched impact strength of all adhe-
sive formulations follow similar trend as indicated in Fig. 5.
The rGO introduction to the epoxy adhesive formulation
increases the izod impact strength, both unnotched and
notched strength up to a plateau (i.e. 30 wt% rGO content)
and then decreases with higher concentration as shown in
Table 4. The epoxy adhesive exhibited unnotched impact
strength of 6.53 kJ/m2. The strength increased to 7.34, 8.68
Fig. 4  Tensile stress–strain graphs of E and ­R10–R50 conductive adhe-
and 9.87 kJ/m2 with the addition of 10, 20 and 30 wt% of
sives rGO which are about 12%, 33% and 51% higher in compari-
son to pure epoxy. However, when the content of rGO was
increased to 40 and 50 wt%, the unnotched impact strength
surface of rGO is susceptible to reaction with epoxy resin diminished by approx. 21% and 32%, respectively as com-
by opening the ring of epoxide group. Further, the epoxy pared to ­R30. The impact strength for unnotched samples
resin reacts with amine group of TETA and simultane- decreased for R­ 40 and R
­ 50 but still higher than that of pristine
ously, the oxygen group of rGO also form chemical bonds epoxy. The enhancement of unnotched impact strength can
with TETA which develop a 3D cross-linked structure. be due to the reinforcing effect of rGO that provide tough-
Hence, this leads to higher tensile strength of adhesive ness to the matrix. The volume fraction of rGO increased
systems. The similar type findings have been detected by with the addition of rGO particles, resulting in higher load
Galicia et al. [29] with combined GO and rGO filler. How- transfer from matrix to rGO which eventually increases the
ever, the lower tensile strength of R ­ 40 and ­R50 adhesive cross-linking of adhesive formulations. This leads to higher
formulations can be ascribed to the formation of clusters unnotched impact strength which has also been noticed by
or aggregates of overloaded rGO particles that behave Li et al. [32]. The decrement can be assigned to the lower
as stress concentrators and lead to early rupture. Similar dispersibility of rGO within the base resin when higher rGO
behaviour has been observed by other researchers [26, 27, content was present, that leads to agglomerated clusters.
30]. The notched impact strength of epoxy resin (1.25 kJ/
As obvious from Table  3, the tensile modulus of m2) was improved by around 54%, 70% and 100% with
­R 10–R 50 adhesive formulations showed contrary results the incorporation of 10, 20 and 30 wt% rGO. This can be
than that of their tensile strength values. With addition of explained with the following arguments: As rGO embraces
10 to 50 wt% rGO particles, the modulus extended up to many oxygen functional groups on its surface, it possesses
3148, 3566, 2851, 3577 and 3752 MPa which are around higher compatibility with the epoxy resin and curing agent
20%, 36%, 9%, 36% and 43% higher than that of pristine which promotes effective dispersibility throughout the resin
epoxy (i.e. 2625 MPa). The improved tensile modulus of (as shown in SEM images, Fig. 6b,c). The larger surface
­R 10–R 50 adhesive formulations can be attributed to the area of rGO significantly increases the toughness of adhesive
immobilization of epoxy chains which is created by the systems which is stated as another reason for impact strength
rGO layers with their platelet geometry. Thus, provided the improvement. Similar behaviour has also been witnessed
reinforcing effect and enhanced the modulus. Equivalent by Tang et al. [33] for GO/epoxy nanocomposites. How-
findings have been noticed by Chhetri et al. [30]. The elon- ever, when the rGO amount increased to 40 and 50 wt%, the
gation at break for conductive adhesive systems ­(R10–R20 notched impact strength decreased by nearly 34% and 40%
and ­R 40–R 50) followed similar response except for R ­ 30 while reaching a value of 1.65 and 1.49 kJ/m2 as compared
system. With the incorporation of rGO particles into the to ­R30 adhesive system (2.50 kJ/m2). The diminution can be
base resin, the elongation at break diminished which can due to the immoderate interfacial contacts (as represented in
be ascribed to the higher aspect ratio of rGO layers and SEM micrograph of ­R50: Fig. 6d) between both the rGO/rGO
interaction between the epoxy resin and rGO particles, layers and rGO/epoxy matrix, that diminished the notched
that impedes the polymer chain movements and as a con- impact strength. Similar findings have also been detected
sequence lowers the elongation [31]. by Lee et al. [34].

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Journal of Materials Science: Materials in Electronics

Scheme 1  Illustrative diagram
for possible interactions
between DGEBA epoxy resin,
rGO and TETA curing agent

4.4 Scanning electron microscopy (SEM) river-like profiles. This result demonstrates the lower frac-
ture toughness and impact strength of unmodified epoxy
To examine the interfacial adhesion between rGO and epoxy resin during impact failure. Similar behaviour has also
resin extensively, the fractured surfaces of notched impact been witnessed in our previous paper [35] and by Singh
samples for all adhesive formulations were visualized by et al. [24, 25]. On the other hand, all the E–rGO conduc-
using SEM as shown in Fig. 6. tive adhesives showed rough or coarser fracture surfaces as
From Fig. 6, it can be clearly visible that unmodified the rGO content increases. In addition, the fracture zones
epoxy adhesive represented a brittle fracture (as shown in generated in various orientations, which may be triggered
Fig. 6a) with the smooth and clear surface along with some due to the random dispersion of rGO layers within the

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Journal of Materials Science: Materials in Electronics

Table 4  Impact strength of E and E–rGO adhesive formulations 4.5 Transmission electron microscopy (TEM)
Sample Un-notched impact strength Notched impact
(kJ/m2) strength (kJ/m2) The morphology and dispersion level of rGO layers in the
­R30 adhesive formulation was evaluated by TEM for cor-
E 6.53 ± 2.86 1.25 ± 0.58
roborating the higher electrical conductivity of the system.
R10 7.34 ± 2.95 1.92 ± 0.62
Figure 7 represents the TEM images of the ­R30 system at
R20 8.68 ± 3.08 2.12 ± 0.74
different magnification levels.
R30 9.87 ± 3.16 2.50 ± 0.55
From TEM micrographs (Fig. 7 a, b), it is clear that the
R40 7.82 ± 2.74 1.65 ± 0.68
black or grey hair-like structures indicate the cross-sectional
R50 6.71 ± 3.12 1.49 ± 0.83
portions of rGO layers. The rGO layers are dispersed homo-
geneously or uniformly throughout the epoxy matrix (as
indicated by red arrows) along with small aggregates (as
highlighted by yellow arrows). The individual or ultra-thin
layer seems transparent, while stacked layers of rGO appear
dark in colour. The uniform dispersion or exfoliation of rGO
layers is because of the interfacial interactions between the
epoxy resin and oxygen functional groups of rGO sheets
[1]. The TEM images showed the edges of rGO layers are
overlapping with each other, constructing efficient electri-
cal pathways within the epoxy matrix, which ultimately
improved the electrical conductivity of the adhesive system.
As rGOs are the stacked layers of GO after removal of oxy-
gen functionalities upon reduction process, they possess less
number of functional groups and can construct conductive
paths for electron transport. Hence, this indicates the reason
for higher electrical conductivity of R ­ 30 adhesive system.
Fig. 5  Unnotched and notched impact strength variation of conduc- Similar behaviour has also been noticed by Sun et al. [37].
tive adhesives against rGO loading
4.6 Electrical conductivity
epoxy matrix [36]. In the case of R
­ 10 and R
­ 30 adhesive for-
mulations, the rGO layers seem to be thoroughly dispersed The electrical conductivities of adhesive formulations as a
in the matrix, as agglomerated clusters aren’t encountered function of rGO loading along two directions i.e. through-
in Fig. 6 b, c. This suggests that rGO layers are tightly the-thickness (volume conductivity, σv) and in-plane (sur-
embedded in the epoxy resin with negligible cleavages face conductivity, σs) are listed in Table 5 and log curves of
around rGO layers, which reveals strong interfacial adhe- electrical conductivities are shown in Fig. 8.
sion/interactions between the rGO layer and epoxy matrix. The volume and surface conductivity of unmodified
Hence, the dispersed rGO layers block the easy crack prop- epoxy adhesive was found to be gradually increasing with
agation leading to higher impact strength of R ­ 10 and R
­ 30 the addition of rGO from 10 to 50 wt%. The epoxy resin
systems than that of the R­ 50 adhesive system. However, possessed volume and surface conductivity of 1.13 × 10−13
as shown in Fig. 6 d, the R ­ 50 adhesive system exhibits S/m and 2.35 × 10−11 S, respectively which evidence insu-
aggregated structures (as highlighted by red circles) which lating characteristics of the epoxy material. In the case of
can be due to the Van der Waals forces within the planar E–rGO conductive adhesives, the σv values reached from
geometries of rGO layers. The aggregated clusters behave 1.13 × 10−13 S/m to 1.09 × 10−12, 7.35 × 10−12, 2.28 × 10−11,
as stress concentrators and promote fracture around it, 1.37 × 10−08 and 3.44 × 10−08 S/m for R ­ 10, ­R20, ­R30, ­R40
resulting in lower impact strength. As described by Liu and ­R50 adhesives which are around one, one, two, five
et al. [36], crack bowing or crack pinning mechanism is and five order of magnitude, respectively higher than that
a usually-known toughening mechanism that simplifies of epoxy adhesive. In addition, the σs of ­R10–R50 conduc-
the reason of higher impact strength for rGO filled epoxy tive adhesives enhanced by one, four, four, five and fivefold
adhesive systems. After addition of stiff and rigid rGO with 1.05 × 10−10, 1.48 × 10−07, 6.85 × 10−07, 2.89 × 10−06
layers in the epoxy matrix, the crack fronts may bow or and 8.54 × 10 −06 S values as compared to pure epoxy
pinned or it may deflect from its original path generat- (2.35 × 10−11 S). Therefore, the electrical percolation thresh-
ing secondary cracks. Thus, require more energy for crack old (EPT) for E–rGO conductive adhesives was determined
propagation and results in improved impact strength. to be at 40 and 20 wt% of rGO loading in the case of σv

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Journal of Materials Science: Materials in Electronics

Fig. 6  SEM images a E, b ­R10, c ­R30 and d ­R50 adhesive formulations. (Color figure online)

Fig. 7  a, b TEM micrograph of ­R30 adhesive formulation at different magnification. (Color figure online)

and σs, respectively. When 40 wt% rGO was included, the the electrical conductivity increases abruptly and then fol-
σv value improved abruptly by five order of magnitude, lowed by a steady increment. The EPT is an indication for
while the σs showed subsequent increase of four order with the formation of 3D conductive network within the insu-
20 wt% addition as compared to unmodified epoxy. Hence, lating polymer matrix. As noticeable from Table 5, the in-
the EPT is known as the critical filler concentration, at which plane conductivity for conductive adhesives is higher than

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Journal of Materials Science: Materials in Electronics

Table 5  Volume and surface conductivity of E and E–rGO adhesive Table 6  Thermal conductivity of E and R
­ 10–R50 adhesive systems
formulations
Sample Thermal conductivity (W/mK)
Sample Volume conductivity (σv) Surface con-
(S/m) ductivity (σs) 35 °C 55 °C 75 °C 95 °C
(S)
E 0.185 0.21 0.228 0.24
E 1.13 × 10−13 2.35 × 10−11 R10 0.32 0.35 0.36 0.39
R10 1.09 × 10−12 1.05 × 10−10 R20 0.44 0.46 0.48 0.51
R20 7.35 × 10−12 1.48 × 10−07 R30 0.61 0.64 0.66 0.67
R30 2.28 × 10−11 6.85 × 10−07 R40 0.83 0.85 0.86 0.89
R40 1.37 × 10−08 2.89 × 10−06 R50 0.94 0.95 0.97 0.98
R50 3.44 × 10−08 8.54 × 10−06

Fig. 8  Log curves of electrical conductivity (σv & σs) of epoxy and


Fig. 9  Thermal conductivity of epoxy based adhesive formulations as
conductive adhesive formulations
a function of rGO concentration

through-the-thickness conductivity, revealing the effective electron can tunnel through adjacent rGO layers. (b) direct
maintenance of electrical contacts between the adjacent rGO contacts between the rGO layers- when the rGO concentra-
layers along in-plane direction than in through-the-thickness tion increases, they physically contact one another and forms
direction. Same behaviour has also been observed in our a conductive network for electron transfer [39].
previous paper [19] and by Yosefi et al. [38, 39]. The elec-
trical conductivity increment with the addition of rGO can
be ascribed to the construction of electrical pathways by the 4.7 Thermal conductivity
rGO layers throughout the epoxy matrix which convert the
insulating epoxy into a conductive material. The electrical The thermal conductivity values of E and ­R10–R50 adhe-
paths formation can be understood with the following two sive formulations at various temperatures were studied. The
reasons: (a) the interactions between the rGO layers and obtained ­Tc values are tabulated in Table 6 and illustrated
epoxy resin (π–π interactions) and between the rGO–rGO in Fig. 9.
layers which leads to the generation of highly dense rGO The thermal conductivity values of unmodified epoxy
percolation networks [40, 41]. This can be confirmed by and conductive adhesive systems exhibited similar trend,
SEM images (Fig. 6b–d) of conductive adhesives. (b) due to such as T­ c increased with the temperature increment from
the larger surface area of rGO sheets, the edges can be easily 35 to 95 °C. The increasing trend of ­Tc with temperature is
overlapped with each other forming conductive paths along ascribed to the expansion of polymer matrix which dispersed
with lower contact resistance as shown in Fig. 7a,b [37]. the rGO layers for constructing the conductive network. As
The electron transfer within the conductive adhesives can the temperature increases, the rGO layers compressed with
be explained with the following mechanisms: (a) electron one another start to disperse thoroughly within the matrix,
tunnelling between the adequately close rGO layers. As the which form the conductive network resulted in T ­ c improve-
rGO layers are segregated by a narrow layer of epoxy, the ment owing to the expansion of polymer matrix [19].

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Journal of Materials Science: Materials in Electronics

With the addition of rGO particles, the ­Tc values of 4.8 FTIR spectroscopy
conductive adhesives followed an improving tendency as
observed from Table 6. At 35 °C, the T ­ c increases from Figure 10 depicts the FTIR spectra of rGO filler along with
0.185 W/mK for E to 0.32 for ­R10, 0.44 for R ­ 20, 0.61 for the E and ­R30 adhesive systems. The spectrum for rGO
­R 30, 0.83 for ­R 40 and 0.94 W/mK for ­R 50 adhesive sys- unveils the characteristics peaks while E and R­ 30 systems dis-
tems which are an increase of around 73%, 138%, 230%, played almost identical behaviour. The IR spectrum of rGO
349% and 408%, respectively. Additionally, in comparison reveal two eminent peaks at 1712.4 cm−1 can be appointed
to ­Tc value for E at 95 °C, the ­Tc improved by about 63%, to the stretching vibration of C=O and at 1058.1 cm−1 can
113%, 179%, 271% and 308% for ­R10, ­R20, ­R30, ­R40 and be designated as C–O stretching vibration, proclaiming the
­R50 adhesive systems, respectively. The improvement of existence of few oxygen functional groups susceptible to
­Tc values with the inclusion of rGO particles can be inter- react with DGEBA resin or TETA as illustrated in Scheme 1
preted as follows: (a) the intrinsic T
­ c and thin layer struc- [45]. The major transmittance peaks of unmodified epoxy
ture of rGO can certainly form a 3D thermal conductive adhesive (as shown in Fig. 10) are at 3378.8 cm−1 for O–H
network within the epoxy matrix as can be observed from stretching vibration, at 2926.8 and 2862.8 cm−1 ascribed
SEM images, Fig. 6b–d. The 3D network of rGO layers to asymmetric and symmetric C–H stretching vibration
can effectively transport heat within the epoxy matrix and respectively, at 1723.3 cm−1 due to C=O stretching, at 1412,
increases the ­Tc value [42]. (b) As high content of rGO 1382.7 and 1292.4 cm−1 (for in-plane bending vibrations of
particles were used, the inter-particle spacing decreases –OH groups), at 1241.6 cm−1 designated for epoxy group, at
and as a result mean free path between the rGO layers for 1179.9 cm−1 (due to C–O–C asymmetric stretching vibration
phonon transfer also decreases. This leads to the formation for ester), at 1030.8 cm−1 ascribed to aromatic C–O stretch-
of conductive network with particle–particle contact and ing vibration and the most intensive peak at 825.2 cm−1 can
improves the ­Tc of adhesive. Similar findings have also be appointed to the oxirane group of epoxy resin [18, 46]. In
been detected by Olowojoba et al. [43]. (c) The residual the case of R ­ 30 adhesive system, IR spectra showed a lower
functional groups present on the planar geometry of rGO intensity peak at 1714.5 cm−1 which is in-between the peak
furnished a better compatibility with epoxy resin. Addi- of rGO (1712.4 cm−1) and E adhesive (1723.3 cm−1). Fur-
tionally, the functionalities can behave as a bridge between ther, the peak for oxirane group of epoxy at 825.2 cm−1 (for
the rGO layers and epoxy resin, which may diminish the epoxy resin) shifted to a lower wavenumber i.e. 798.5 cm−1
contact resistance and enhance the ­Tc values of adhesive indicate the effective interaction of rGO with epoxy matrix.
formulations. Similar discussion has also been reported Similar findings have also been detected by Singh et al. [18].
by Tang et al. [44]. Table 7 summarizes the major functional groups of E and
­R30 adhesive systems along with functional groups of rGO
filler.

4.9 Thermo‑gravimetric analysis (TGA)

To examine the influence of rGO filler on the thermal deg-


radation behaviour and stability of epoxy resin, TG analysis

Table 7  Detail of functional groups of rGO and a comparison of


major functional groups of E and ­R30 adhesive systems
Functional groups Characteristics transmittance (ν,
­cm−1)
rGO E R30

O–H stretching – 3378.8 3367.1


CH2 (asymmetric stretching) – 2926.8 2925.9
CH2 (symmetric stretching) – 2862.8 2864.3
Asymmetric C═O stretching 1712.4 1723.3 1714.5
Asymmetric C–O–C stretching – 1179.9 1177.6
C–O stretching 1058.1 – –
Aromatic C–O stretching – 1030.8 1009.3
Epoxy group – 825.2 798.4
Fig. 10  FTIR spectra of rGO particles, E and R
­ 30 adhesive systems

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Journal of Materials Science: Materials in Electronics

Fig. 11  a TGA and b DTG thermograms of E and ­R30 adhesive formulation

was conducted and the corresponding TGA and DTG ther- which behaves as barrier and detains the degradation of
mograms are depicted in Fig. 11a,b. The obtained param- epoxy matrix. As shown in Fig. 7 (TEM images), the rGO
eters from TGA and DTG curves such as 10% weight loss layers attain an effective dispersion throughout the epoxy
temperature ­(T10%), 50% weight loss temperature (­ T50%), first matrix which can easily hinder the segmental movement of
degradation temperature (­ Tonset), maximum degradation tem- epoxy chains in-between them while delaying their volatile
perature ­(Td(max)), final degradation temperature ­(Tendset) and decomposition [19]. In addition, due to the strong interfacial
% weight remaining at 650 °C ­(CR650) are summarized in interaction between rGO and DGEBA resin (as illustrated
Table 8. in Scheme 1), leads to higher crosslinking density network
The TGA graphs as depicted in Fig. 11a denoted two and concluded in higher degradation temperature [30]. The
stage degradation process for base epoxy adhesive whilst % weight remained at 650 °C for ­R30 adhesive system was
­R30 system showed one-stage degradation profile. The first found to be substantially higher i.e. 25.7% as compared to
stage degradation of E where major weight loss occurred unmodified epoxy resin. When the epoxy resin is reinforced
at around 270–365 °C that can be due to the main epoxy with the rGO filler, results in higher char retention that can
chain pyrolysis and the second stage about 475–660 °C can be attributed to the existence of carbon net structure which
be attributed to the decomposition of epoxy network after impedes the generation of gaseous product [47].
curing [19]. Similar trends have also been noticed by other
researchers [25, 35]. However, the R ­ 30 system exhibited
one step degradation in the range of 260–380 °C with sig- 5 Conclusion
nificant weight loss and afterwards the formation of char
residue. Addition of 30 wt% rGO within the epoxy resin In the present study, an attempt has been done to prepare an
increased both ­T10% and ­T50% by 4 °C and 5 °C, respectively electrically conductive epoxy adhesive filled with the high
as compared to virgin epoxy. Further, the T ­ onset which nar- content of rGO (i.e. 10–50 wt%). The lap shear test was
rates the first degradation temperature of adhesive system performed to study the adhesive strength of epoxy-based
and ­Td(max) showed 14 °C and 10 °C increment over epoxy adhesive systems. The test results revealed that adhesive
resin. As the R­ 30 adhesive system displayed single step deg- with 40 wt% rGO possessed highest shear strength which
radation profile, the ­Tendset value diminished by 211 °C than is 72.8% higher over unmodified epoxy. While the tensile
that of base line epoxy. Therefore, it can be clearly noticed test results showed a decrement of 33% in tensile strength
from insert of Fig. 11a that ­R30 adhesive system possessed even with the introduction of 10 wt% rGO. The unnotched
higher thermo-stability as compared to epoxy resin. This and notched impact strength of epoxy resin found to be
can be ascribed to the ‘tortuous path effect’ of rGO layers increasing up to 51% and 100% respectively, when 30 wt%

Table 8  TGA and DTG data of Samples T10% (°C) T50% (°C) Tonset (°C) Td(max) (°C) Tendset (°C) CR650 (%)
E and ­R30 adhesive systems
E 331 368 271 343 662 0.3
R30 335 373 285 353 451 26

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Journal of Materials Science: Materials in Electronics

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